Valve Stem Seals, Removing And Installing, Cylinder Head Removed

Special tools and workshop equipment required 

• Puller - Valve Seal: 3364 
• Intake side: Seal Installer - Valve Stem: 3365 
• Exhaust side: Valve Stem Seal Driver: T40376/2 
• Valve Keeper Tool Kit: VAS5161A  with Valve Keeper Tool Kit - Guide Plate 2.5L TFSI: VAS5161A/39 
• Engine and Gearbox Bracket VAS6095A: VAS6095A 
• Cylinder Head Tensioning Device: VAS6419 
• Pliers - Valve Seal: VAS6770 
• Mounting Sleeve. Refer to the Parts Information.

Procedure 

• Turbocharger removed. Refer to TURBOCHARGER, REMOVING AND INSTALLING .

-- Mark the allocation of the roller rocker lever and the hydraulic lifter so they can be installed again.

-- Remove the roller rocker lever with the hydraulic lifter and place them on a clean surface.

-- Insert the : VAS6419  in the : VAS6095A  .

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-- Tension the cylinder head on the cylinder head tensioning device, as shown.

-- Connect the cylinder head tensioning device to compressed air.

-- Slide the air cushion with the lever -arrow- under the combustion chamber onto the valve stem seal that will be removed.

-- Let enough compressed air flow into the air cushion until it contacts the valve plate.

-- Secure the : VAS5161A/39  .

-- Set the : VAS5161/19C  on the cylinder head.

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-- Secure the guide plate with the : VAS5161/12  .

-- Position the : VAS5161/3A  on the valve spring plate and loosen the stuck valve keepers with a plastic mallet.

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-- Install the : VAS5161/6  with the : VAS5161/5  in the guide plate.

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-- Push the : VAS5161/8A  into the guide plate.

-- Engage the : VAS5161/2  at the engaging device and press the installation cartridge downward.

-- At the same time, turn the installation cartridge knurled bolt right until points engage in the valve keepers.

-- Move the knurled bolt left and right slightly. This presses the valve keepers apart and captures them in the assembly cartridge.

-- Release the pressure fork.

-- Remove the assembly cartridge.

-- Remove the guide plate and turn it aside.

-- Remove the valve spring and the valve spring retainer.

-- Remove the valve stem seal using the : 3364  or the : VAS6770  .

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-- Lightly oil the valve stem seal sealing lip.

Intake Side: 

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• In order not to damage the valve stem seal -4- during installation, mount the Mounting Sleeve -3- on the valve stem -2-.

-- Lightly oil the valve stem seal sealing lip.

-- Insert the valve stem seal in the : 3365  and carefully press on the valve guide -1- all the way.

-- Remove the mounting sleeve.

Exhaust Side: 

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• In order not to damage the valve stem seal -4- during installation, mount the Mounting Sleeve -3- on the valve stem -2-.

-- Lightly oil the valve stem seal sealing lip.

-- Insert the valve stem seal in the : T40376/2  and carefully press on the valve guide -1- all the way.

-- Remove the mounting sleeve.

If the valve keepers were removed from the assembly cartridge, they must then be inserted into the : VAS5161/18  .

• The large diameter of the valve keepers point upward.

-- Press the cartridge from above onto the insertion device and valve keepers.

-- Insert the valve spring and the valve spring retainer. Refer to Figure.

-- Attach the : VAS5161A/39  again on the cylinder head.

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-- Insert the assembly cartridge into the guide plate.

-- Press the pressure fork down and pull the knurled bolt up while turning left and right. This inserts the valve keepers.

-- Release the pressure fork with the knurled bolt still raised.

-- Repeat the procedure on each valve.

Assembling 

Assemble in the reverse order of removal. Note the following:

-- Make sure all the roller rocker levers lie correctly on the ends of the valve stems and are clipped onto the respective hydraulic lifters.